Hyundai Manuals - Service Manual

Full text

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The operator manual contains a number of instructions and safety recommendations

regarding driving, handing, lubrication, maintenance, inspection and adjustment of the

equipments.

The manual is to promote safety maintenance and enhance machine performance.

The service manual has been prepared as an aid to improve the quality of repairs by giving

the serviceman an accurate understanding of the product and showing him the correct way to

perform repairs and make judgments. Make sure you understand the contents of this manual

and use it to full effect at every opportunity.

This service manual mainly contents the necessary technical information for operation

performed in a service workshop.

Ask manuals

brovertekgr@gmail.com

. Specify machine and model what you need.

Example: Crawler Excavator R210LC-7.

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Foreword - - - 0-1 Before servicing this machine - - - 0-2 EC regulation approved - - - 0-3 Table to enter S/No and distribution - - - 0-4 Safety labels - - - 0-5 Guide(Direction, S/No, Symbol) - - - 0-15

SAFETY HINTS

1. Before operating the machine - - - 1-1 2. During operating the machine - - - 1-6 3. During maintenance - - - 1-13 4. Parking - - - 1-16

SPECIFICATIONS

1. Major components - - - 2-1 2. Specifications - - - 2-2 3. Working range - - - 2-5 4. Weight - - - 2-8 5. Lifting capacities - - - 2-11 6. Bucket selection guide - - - 2-18 7. Undercarriage - - - 2-20 8. Specification for major components - - - 2-22 9. Recommended oils - - - 2-26

CONTROL DEVICES

1. Cab devices - - - 3-1 2. Cluster - - - 3-2 3. Switches - - - 3-9 4. Levers and pedals - - - 3-14 5. Air conditioner and heater - - - 3-17 6. Others - - - 3-20

OPERATION

1. Suggestion for new machine - - - 4-1 2. Check before starting the engine - - - 4-2 3. Starting and stop the engine - - - 4-3 4. Mode selection system - - - 4-7 5. Operation of the working device - - - 4-14

6. Traveling of the machine - - - 4-15 7. Efficient working method - - - 4-18 8. Operation in the special work sites - - - 4-23 9. Normal operation of excavator - - - 4-24 10. Attachment lowering - - - 4-25 11. Storage - - - 4-26 12. RCV lever operating pattern - - - 4-28 13. Switching hydraulic attachment circuit - - - 4-29

TRANSPOTATION

1. Preparation for transportation - - - 5-1 2. Dimension and weight - - - 5-2 3. Loading the machine - - - 5-4 4. Fixing the machine - - - 5-6 5. Loading and unloading by crane - - - 5-7

MAINTENANCE

1. Instruction - - - 6-1 2. Tightening torque - - - 6-6 3. Fuel, coolant and lubricants - - - 6-9 4. Maintenance check list - - - 6-11 5. Maintenance chart - - - 6-16 6. Service instruction - - - 6-18 7. Electrical system - - - 6-40 8. Air conditioner and heater - - - 6-43

TROUBLESHOOTING GUIDE

1. Engine - - - 7-1 2. Electrical system - - - 7-2 3. Others - - - 7-3

HYDRAULIC BREAKER AND QUICK CLAMP

1. Selecting hydraulic breaker - - - 8-1 2. Circuit configuration - - - 8-2 3. Maintenance - - - 8-3 4. Precaution while operating the breaker - - - 8-4 5. Quick clamp - - - 8-6

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ENGINE

Item Type

Capacity

Maximum pressure Rated oil flow Rated speed

Specification

Variable displacement tandem axis piston pumps

2Ý105cc/rev *2Ý113cc/rev

330kgf/cm2(4694psi) [360kgf/cm2(5120psi)]

2Ý220˶/min (58.1U.S. gpm/ 48.4U.K. gpm)

2100rpm *1950rpm

8

8. SPECIFICATIONS FOR MAJOR COMPONENTS

1)

Item Model

Type

Cooling method

Number of cylinders and arrangement Firing order

Combustion chamber type

Cylinder boreÝstroke

Piston displacement Compression ratio

Rated gross horse power(SAE J1995

Maximum torque at 1600rpm *at 1500rpm

Engine oil quantity Dry weight High idling speed Low idling speed Rated fuel consumption Starting motor

Alternator Battery

Specification

Cummins B5.9-C *Cummins 6BTAA 4-cycle turbocharged diesel engine, low emission Water cooling

6 cylinders, in-line 1-5-3-6-2-4 Direct injection type

102Ý120mm(4.02"Ý4.72") 5880cc(359cu in) 17.4 : 1 *17.3 : 1 155Hp at 2100rpm(116kW at 2100rpm) *150Hp at 1950rpm(112kW at 1950rpm) 62.1kgfÂm(450lbfÂft) *62.6kgfÂm(453lbfÂft) 24˶(6.3U.S. gal) 400kg(882lb) *496kg(1094lb) 2250 50rpm *2180 50rpm 950Ü100rpm *1050Ü100rpm 171.5g/HpÂhr at 2100rpm *164.8g/HpÂhr at 1950rpm Nippon denso(24V-5.5kW) *(24V-4.5kW)

Delco Remy (24V-50A) 2Ý12VÝ100Ah * : TIER II [ ] : Power boost * : TIER II M MAIN PUMP 2)

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GEAR PUMP

MAIN CONTROL VALVE

SWING MOTOR

Item Type

Capacity

Maximum pressure Rated oil flow

Specification

Fixed displacement gear pump single stage 15cc/rev 35kgf/cm2(500psi) 29.3˶/min(7.7U.S. gpm/6.4U.K. gpm) Item Type Operating method Main relief valve pressure Overload relief valve pressure

Specification 9 spools mono-block

Hydraulic pilot system

330kgf/cm2(4695psi)[360kgf/cm2(5120psi)] 390kgf/cm2(5550psi) Item Type Capacity Relief pressure Braking system Braking torque

Brake release pressure Reduction gear type Swing speed

Specification Two fixed displacement axial piston motor 151cc/rev

240kgf/cm2(3414psi)

Automatic, spring applied hydraulic released

59kgfÂm(427lbfÂft) 33~50kgf/cm2(470~711psi) 2 - stage planetary 12.5rpm 3 3) 4) 5) [ ]: Pooer boost TRAVEL MOTOR TRAVEL MOTOR(GM35VL, up to #2078) 6) (1) Item Type Relief pressure Reduction gear type Braking system Brake release pressure Braking torque

Specification Variable displacement axial piston motor

330kgf/cm2(4695psi)

3-stage planetary

Automatic, spring applied hydraulic released

6kgf/cm2(85psi)

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REMOTE CONTROL VALVE

CYLINDER

Item Type

Specification Pressure reducing type

6.5kgf/cm2(92psi) 26kgf/cm2(370psi) 61mm(2.4in) 123mm(4.84in) Operating pressure Minimum Maximum Lever Pedal Single operation stroke

Item Specification

͚120Ý͚85Ý1290mm Extend only

͚140Ý͚100Ý1510mm #͚140Ý͚95Ý1460mm

Extend and retract

͚125Ý͚85Ý1055mm #͚100Ý͚70Ý870mm

Extend only Bore diaÝRod diaÝStroke

Cushion

Bore diaÝRod diaÝStroke Cushion

Bore diaÝRod diaÝStroke Cushion Boom cylinder Arm cylinder Bucket cylinder 7 7) 8)

ö Discoloration of cylinder rod can occur when the friction reduction additive of lubrication oil spreads on the rod surface.

ö DDiscoloration does not cause any harmful effect on the cylinder performance.

# : LONG REACH

TRAVEL MOTOR(RMV147, #2079 and up) (2)

Item Type

Relief pressure Reduction gear type Braking system Brake release pressure Braking torque

Specification Variable displacement axial piston motor

330kgf/cm2(4695psi) ø325kgf/cm2(4625psi)

2-stage planetary

Automatic, spring applied hydraulic released

11kgf/cm2(156psi) ø11kgf/cm2(157psi)

49.3kgfÂm(357lbfÂft) ø49.3kgfÂm(357lbfÂft)

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Capacity

SAE heaped Without side cutter

Width Item 0.92m3(1.20yd3) 0.51m3(0.67yd3) 0.80m3(1.05yd3) 1.10m3(1.44yd3) 1.20m3(1.57yd3) 1.34m3(1.75yd3) ľ0.74m3(0.97yd3) ľ0.90m3(1.18yd3) ľ1.05m3(1.37yd3) Ľ0.87m3(1.14yd3) Ľ1.20m3(1.57yd3) Ŀ0.75m3(0.98yd3) 0.80m3(1.05yd3) 0.45m3(0.59yd3) 0.70m3(0.92yd3) 0.96m3(1.26yd3) 1.00m3(1.31yd3) 1.15m3(1.50yd3) 0.65m3(0.85yd3) 0.80m3(1.05yd3) 0.92m3(1.20yd3) 0.75m3(0.98yd3) 1.00m3(1.31yd3) 0.65m3(0.85yd3) 5 3 5 5 6 6 5 5 5 5 5 -1150mm(45.3") 700mm(27.6") 1000mm(39.4") 1320mm(52.0") 1400mm(55.1") 1550mm(61.0") 985mm(38.8") 1070mm(42.0") 1290mm(50.8") 1140mm(44.9") 1410mm(55.5") 1790mm(70.5") 1270mm(50.0") 820mm(32.3") 1120mm(44.1") 1440mm(56.7") 1520mm(59.8") 1670mm(65.7")       Tooth quantity

ľ : Heavy duty bucket Ľ : Rock bucket(Heavy) Ŀ : Slope finishing bucket

R210LC-7 STD OPT B BUCKET 10) SHOE 9) Item Width 600mm(24") 700mm(28") 800mm(32") 800mm(32") 600mm(24") 700mm(28") 800mm(32") ö710mm(28") Ground pressure 0.46kgf/cm2(6.54psi) 0.40kgf/cm2(5.69psi) 0.35kgf/cm2(4.98psi) 0.42kgf/cm2(5.97psi) 0.49kgf/cm2(6.97psi) 0.43kgf/cm2(6.12psi) 0.38kgf/cm2(5.40psi) 0.43kgf/cm2(6.12psi) Link quantity 49 49 49 49 49 49 49 49 Overall width 2990mm(9' 10") 3090mm(10' 2") 3190mm(10' 6") 3190mm(10' 6") 3395mm(11' 2") 3495mm(11' 6") 3595mm(11' 10") 3505mm(11' 6") Standard Standard Standard Option R210LC-7 R210LC-7 LONG REACH R210LC-7 HIGH WALKER Option ö : Double grouser.

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Service Check, Refill Check, Add Check, Add Check, Add Check, Clean Check, Drain Check, Clean Check, Adjust Page 6-25 6-30 6-18 6-20 6-40 6-26 6-26 6-24 Check items Visual check Fuel tank Hydraulic oil level Engine oil level Coolant level

Control panel & pilot lamp Water separator(~#3341) Prefilter(#3342~) Fan belt tension

DAILY SERVICE BEFORE STARTING

4. MAINTENANCE CHECK LIST

EVERY 50 HOURS SERVICE

Service Drain Check, Adjust Lubricate Check, Add Check, Add Lubricate Page 6-25 6-35 6-33 6-33 6-33 6-39 1) 2) Check items Fuel tank(Water sediment)

Track tension

Swing bearing grease Swing reduction gear oil Swing reduction gear grease Lubricate pin and bushing

ÂBoom cylinder tube end ÂBoom foot

ÂBoom cylinder rod end ÂArm cylinder tube end ÂArm cylinder rod end ÂBoom + Arm connecting ÂBucket cylinder tube end ÂBucket cylinder rod end ÂArm + Bucket connecting ÂArm + Link, Bucket control ÂBucket control rod

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Service Change Replace Replace Replace Replace Replace Replace Check, Tight Page 6-18, 19 6-18, 19 6-26-1 6-32 6-31 6-32 6-26-1 6-8 Check items Engine oil Engine oil filter Prefilter(#3342~) Pilot line filter Hydraulic return filter Drain filter cartridge Fuel filter element Bolts & Nuts

ÂSprocket mounting bolts ÂTravel motor mounting bolts ÂSwing motor mounting bolts ÂSwing bearing mounting bolts ÂEngine mounting bolts ÂCounterweight mounting bolts ÂTurning joint locating bolts

ÂTrack shoe mounting bolts and nuts ÂHydraulic pump mounting bolts

I

INITIAL 50 HOURS SERVICE

Service the above items only for the new machine, and thereafter keep the normal service interval.

Service Replace Replace Replace Replace Page 6-31 6-32 6-32 6-32 Check items ø Return filter ø Pilot line filter ø Air breather element ø Drain cartridge filter

E

EVERY 100 HOURS SERVICE

ø Replace 4 filters for continuous hydraulic breaker operation only. 3) 4) Service Change Page 6-33 Check items

Swing reduction gear oil

INITIAL 250 HOURS SERVICE 5)

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Page 6-40 6-31 6-32 6-32 6-44 6-32 6-8 Service Check, Add Replace Replace Replace Check Replace Check, Tight Check items Battery electrolyte Hydraulic oil return filter Drain filter cartridge Pilot line filter

Aircon & heater flesh filter Air breather element Bolts & Nuts

ÂSprocket mounting bolts ÂTravel motor mounting bolts ÂSwing motor mounting bolts ÂSwing bearing mounting bolts ÂEngine mounting bolts ÂCounterweight mounting bolts ÂTurning joint locating bolts

ÂTrack shoe mounting bolts and nuts ÂHydraulic pump mounting bolts

E

EVERY 250 HOURS SERVICE

Service Change Replace Check, Clean Check, Clean Replace Change Page 6-18, 19 6-18, 19 6-23 6-25 6-26-1 6-26 Check items øEngine oil

øEngine oil filter

Radiator, cooler fin and charge air cooler ÷Air cleaner element(Primary)

Fuel filter element Prefilter(#3342~)

E

EVERY 500 HOURS SERVICE

ø If you use high sulfur containing fuel above than 0.5% or use low grade of engine oil reduce change interval.

÷Clean the primary element only after 500 hours operation or when the air cleaner warning lamp blinks. Replace primary element and safety element after 4 times cleanings of primary element.

6 6) 8) Service Change Page 6-34 Check items

Travel reduction gear oil

INITIAL 500 HOURS SERVICE 7)

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Service Change Change Change Page 6-34 6-33 6-33 Check items

Travel motor reduction gear oil Swing reduction gear oil Grease in swing gear and pinion

EVERY 1000 HOURS SERVICE 9) Service Change Check, Clean Change Page 6-31 6-31 6-20, 21, 22, 23 Check items Hydraulic tank øÂOil ÂSuction strainer Coolant E

EVERY 2000 HOURS SERVICE

øChange oil every 600 hours of continuous hydraulic breaker operation.

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WHEN REQUIRED

Whenever you have trouble in the machine, you must perform the service of related items, system by system. 11) Check items Fuel system ÂFuel tank ÂWater separator(~#3341) ÂPrefilter(#3342~) ÂFuel filter element Engine lubrication system ÂEngine oil

ÂEngine oil filter Engine cooling system ÂCoolant

ÂRadiator

ÂCharge air cooler Engine air system ÂAir cleaner element Hydraulic system ÂHydraulic oil ÂReturn filter ÂDrain line filter ÂPilot line filter ÂElement of breather ÂSuction strainer Under carriage ÂTrack tension Bucket ÂTooth ÂSide cutter ÂLinkage ÂBucket assy

Air conditioner and heater ÂFresh filter ÂRecirculation filter Service Drain or Clean Drain or Replace Clean or Replace Replace Change Replace Add or Change Clean or Flush Check Replace Add or Change Replace Replace Replace Replace Clean Check, Adjust Replace Replace Adjust Replace Clean, Replace Clean Page 6-25 6-26 6-26 6-26-1 6-18, 19 6-18, 19 6-20, 21, 22, 23 6-20, 21, 22, 23 6-23 6-25 6-30 6-31 6-32 6-32 6-32 6-31 6-35 6-37 6-37 6-36 6-36 6-43 6-44

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Method of removing the battery cable

Remove the cable from the ground connection terminal side) and reconnect it last when reassembling.

WIRING, GAUGES

Check regularly and repair loose or malfunctioning gauges when found.

Specific gravity of battery

Judge the charging rate of battery by the specific gravity. The specific gravity changes by the ambient temperature.

Check the charging rate by referring to the chart below.

7. ELECTRICAL SYSTEM

BATTERY

Check and repair

Check the electrolyte level and fill with distilled water to the prescribed level as necessary. Wash the terminal with hot water if it is contaminated, and apply grease to the terminals after washing.

Do not stain clothes or skin with electrolyte as it is acid.

Be careful not to get the electrolyte in eyes. Wash with clean water and go to the doctor if it enters the eyes.

Remove the fire and spark around battery.

100% 90% 80% 75% 1.26 1.24 1.22 1.21 1.27 1.25 1.23 1.22 1.28 1.26 1.24 1.23 Temperature 20ÁC (68ÁF) 10ÁC (50ÁF) -10ÁC (14ÁF) Charging rate ( (3) first( Plug Upper level Lower level 10 ~15mm Specific gravity meter Height of sight Battery Battery relay Ground 13036MI29 13036MI30 13036MI31 13036MI32 1) 2) (1) Η Θ ö (2)

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STARTING THE ENGINE WITH A BOOSTER CABLE Keep following order when you are going to start engine using booster cable.

Connection of booster cable

Use the same capacity of battery for starting. Make sure that the starting switches of the normal machine and trouble machine are both at the OFF position.

Connect the red terminal of booster cable to the battery (+) terminal between exhausted and new battery.

Connect the black terminal of the booster cable between new battery (-) terminal and chassis of trouble machine.

Keep firmly all connection, the spark will be caused when connecting finally.

Starting the engine

Starting the engine of the normal machine and keep it to run at high idle.

Start engine of the trouble machine with starting switch.

If you can not start it by one time, restart the engine after 2 minutes.

ON

OFF START

Taking off the booster cable Take off the booster cable(black).

Take off the booster cable(red) connected to the (+) terminal.

Run engine with high idle until charging the exhausted battery by alternator, fully.

Explosive gas is generated while using the battery or charging it. Keep away flame and be careful not to cause the spark.

Charge the battery in the well ventilated place.

Place the machine on the earth or concrete. Avoid charging the machine on the steel plate.

Do not connect (+) terminal and (-) terminal when connecting booster cable because it will be shorted.

Connection of booster cable Red Normal(New) machine Trouble(Exhausted) machine Black To chassis of trouble machine

Connection order : ΗĄΘĄΙĄΚ Ι Θ Η Κ ( (1) ö Η Θ Ι ö

Disconnection of booster cable

Red Normal(New) machine Trouble(Exhausted) machine Black To chassis of trouble machine

Disconnection order : ΚĄΙĄΘĄΗ Ι Θ Η Κ 13036MI33 13036MI33 21076MA29 ( (2) Η Θ Ι ( (3) Η Θ Ι ö ö ö 3)

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Welding repair

Before start to welding, follow the below procedure.

Shut off the engine and remove the starting switch.

Disconnect ground cable from battery by master switch.

Before carrying out any electric welding on the machine, the battery cables should be disconnected and the connectors pulled out of the electronic control units(CPU, cluster etc). Connect the earth(ground) lead of the welding equipment as close to the welding point as possible.

Do not weld or flame cut on pipes or tubes that contain flammable fluids. Clean them thoroughly with nonflammable solvent before welding or flame cutting on them.

Do not attempt to welding work before carry out the above.

If not, it will caused serious damage at electric CAPO system.

CPU Controller Y RG MODEL:R OBEX 450LC-7 PART NO:21 NB-32110 CN-51 CN-50 HYUNDAI Work Mode User M ode Auto Dece l Power Mode Travel Speed Select Cluster CN-56 OFF Master switch Battery (4) Η Θ Ι Κ ö 21076MI35

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INDEX TROUBLESHOOTING

SECTION 1 Group 1 Before troubleshooting

GENERAL Group 2 Hydraulic and Mechanical System Group 1 Safety Hints Group 3 Electrical System

Group 2 Specifications Group 4 Mechatronics System

SECTION 2 Group 5 Mechatronics System(#1001 and up,Tier 2)

STRUCTUREND FUNCTION SECTION 7

Group 1 Pump Device MAINTENANCE STANDARD

Group 2 Main Control Valve Group 1 Operational Performance Test Group 3 Swing Device Group 2 Major Components

Group 4 Travel Device Group 3 Track and Work Equipment Group 5 RCV Lever SECTION 8

Group 6 RCV Pedal DISASSEMBLY AND ASSEMBLY

SECTION 3 Group 1 Precaution

HYDRAULIC SYSTEM Group 2 Tightening Torque Group 1 Hydraulic Circuit Group 3 Pump Device Group 2 Main Circuit Group 4 Main Control Valve Group 3 Pilot Circuit Group 5 Swing Device Group 4 Single Operation Group 6 Travel Device Group 5 Combined Operation Group 7 RCV Lever

SECTION 4 Group 8 Turning Joint

ELECTRICAL SYSTEM Group 9 Boom, Arm and Bucket Cylinder Group 1 Component Location Group 10 Undercarriage

Group 2 Electrical Circuit(up to #1000) Group 11 Work Equipment Group 3 Electrical Component Specification SECTION 9

Group 4 Connectors COMPONENT MOUNTING TORQUE Group 5 Electrical Circuit(#1001 and up, Tier 2) Group 1 Introduction guide

SECTION 5 Group 2 Engine system

MECHATROMICS SYSTEM Group 3 Electric system Group 1 Outline(up to #1000) Group 4 Hydraulic system Group 2 Mode selection System(up to #1000) Group 5 Undercarriage Group 3 Automatic Deceleration System Group 6 Structure

Group 4 Power Boost System Group 7 Work equipment Group 5 Travel Speed Control System

Group 6 Automatic Warming Up Function Group 7 Engine Overheat Prevention Function Group 8 Anti-Restart System

Group 9 Self-Diagnostic System Group 10 Engine Control System

Group 11 EPPR(Electro Proportional Pressure Reducing) Valve

Group 12 Prolix Switch(up to #0179) Group 13 Monitoring System

Group 14 Outline(#1001 and up, Tier 2)

Group 15 Mode selection system (#1001 and up, Tier 2)

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GROUP 6 AUTOMATIC WARMING UP FUNCTION

Main pump Pilot pump

EPPR valve Drive signal P M Engine Coolant temp sensor Fuel injection pump Accel actuator CPU controller

Warming up lamp signal

Coolant temperature signal Potentiometer signal Motor drive signal

Max flow CO valve

CPU controller reads engine coolant temperature through the temperature sensor, and if the coolant temperature is less than 30°C, it increases the engine speed from key start rpm to 1200rpm. At this time the mode does not change.

In case of the coolant temperature increases up to 30°C,the engine speed is decreased to key start speed. And if an operator changes mode set during the warming up function, the CPU controller cancels the automatic warming up function.

3. LOGIC TABLE 1. 2. Actuated Canceled Warming up lamp - Coolant temperature :

Less than 30°C(After engine run)

- Accel dial position is under 3

- Coolant temperature : Above 30°C

- Warming up time : Above 10 minutes - Changed mode set by operator - Increase engine speed by rotating accel

dial clockwise

※ If any of the above conditions is applicable, the automatic warming up function is canceled

- Coolant temperature : Above 30°C

- Mode : Default(S mode)

- Warming up time : 10 minutes(Max) - Warming up lamp : ON

- Default mode - Default mode - Changed mode

- Warming up lamp : OFF

Description Condition Function

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1. REMOVAL AND INSTALL

REMOVAL

Lower the work equipment to the ground and stop the engine.

Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping

Loosen the breather slowly to release the pressure inside the hydraulic tank.

Escaping fluid under pressure can penetrate the skin causing serious injury. Loosen the drain plug under the hydraulic tank and drain the oil from the hydraulic tank.

・ Hydraulic tank quantity : 180ℓ

Remove socket bolts(74) and disconnect pipe(9).

Disconnect pilot line hoses(4, 5, 6, 7, 8, 9). Remove socket bolts(72) and disconnect pump suction tube(3).

When pump suction tube is disconnected, the oil inside the piping will flow out, so catch it in oil pan.

Sling the pump assembly and remove the pump mounting bolts.

・ Weight : 120kg(265lb)

Pull out the pump assembly from housing. When removing the pump assembly, check that all the hoses have been disconnected.

GROUP 3 PUMP DEVICE

A1 A2 9 74 72 3 48 49 55 69 71 64 58 78 A3 B3 Pm2 Pm1 Psv Dr a4 Pi1 Pi2 1) (1) (2) (3) (4) (5) (6) (7) ※ (8) ※ 13031GE18 21078DA01 21078DA02

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INSTALL

Carry out installation in the reverse order to removal.

Remove the suction strainer and clean it. Replace return filter with new one. Remove breather and clean it.

After adding oil to the hydraulic tank to the specified level.

Bleed the air from the hydraulic pump. Remove the air vent plug(2EA). Tighten plug lightly.

Start the engine, run at low idling, and check oil come out from plug.

Tighten plug.

Start the engine, run at low idling(3~5 minutes) to circulate the oil through the system.

Confirm the hydraulic oil level and check the hydraulic oil leak or not.

2) (1) (2) (3) (4) (5) (6) ① ② ③ ④ (7) (8)

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2. MAIN PUMP(1/2)

STRUCTURE 1) 04 Gear pump 111 Drive shaft(F) 113 Drive shaft(R) 114 Spline coupling 123 Roller bearing 124 Needle bearing 127 Bearing spacer 141 Cylinder block 151 Piston 152 Shoe 153 Set plate 156 Bushing 157 Cylinder spring 158 Spacer 211 Shoe plate 212 Swash plate 214 Bushing 251 Support 261 Seal cover(F) 271 Pump casing 312 Valve block 313 Valve plate(R) 314 Valve plate(L) 401 Hexagon socket bolt 406 Hexagon socket bolt 466 VP Plug 468 VP Plug 490 Plug 531 Tilting pin 532 Servo piston 534 Stopper(L) 535 Stopper(S) 548 Pin 702 O-ring 710 O-ring 717 O-ring 724 O-ring 725 O-ring 728 O-ring 732 O-ring 774 Oil seal 789 Back up ring 792 Back up ring 806 Hexagon head nut 808 Hexagon head nut 824 Snap ring 885 Pin 886 Spring pin 901 Eye bolt 953 Set screw 954 Set screw 789, 732 532 214 548 531 724 792 534 901 808 954 717 151 152 211 113 04 535 806 953 886 717 406 261 774 111 824 127 710 123 251 212 A 702 490 153 156 158 157 468 313 124 312 114 466 885 314 141 271 401 728 725 (210-7) 8-9

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MAIN PUMP(2/2)

541 Seat 543 Stopper 1

544 Stopper 2 545 Steel ball

079 Proportional reducing valve

544 543 545 541 079 VIEW A (210-7) 8-10

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TOOLS AND TIGHTENING TORQUE Tools

The tools necessary to disassemble/reassemble the pump are shown in the follow list. 2)

(1)

Hexagon socket head bolt

Hexagon socket

head bolt Henagon nut

VP plug (PF thread) M 5 M 6 M 8 M10 M20, M22 M12 M16 M18 M20 -M12 M16 M18 M20 -VP-1/4 -VP-1/2 -VP-3/4 BP-1/16 BP-1/8 BP-1/4 BP-3/8 BP-1 -PO-1/4 PO-3/8 PO-1, 1 1/4, 1 1/2 M 8 M10 M12, M14 M16, M18 -PT plug (PT thread) PO plug (PF thread) Hexagon socket head setscrew Name

Tool name & size Part name

Allen wrench

Double ring spanner, socket wrench, double(Single)

open end spanner B B B 4 5 6 8 17 -19 24 27 30 36 Adjustable angle wrench

Screw driver Hammer Pliers Steel bar Torque wrench

Medium size, 1 set

Minus type screw driver, Medium size, 2 sets Plastic hammer, 1 set

For snap ring, TSR-160

Steel bar of key material approx. 10×8×200 Capable of tightening with the specified torques

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Tightening torque (2)

Part name

Hexagon socket head bolt Material : SCM435)

PT Plug(Materal : S45C) ※Wind a seal tape 1 1/2 to 2

turns round the plug

PF Plug(Materal : S45C) M 5 M 6 M 8 M10 M12 M14 M16 M18 M20 PT1/16 PT 1/8 PT 1/4 PT 3/8 PT 1/2 PF 1/4 PF 1/2 PF 3/4 PF 1 PF 1 1/4 PF 1 1/2 0.7 1.2 3.0 5.8 10.0 16.0 24.0 34.0 44.0 0.7 1.05 1.75 3.5 5.0 3.0 10.0 15.0 19.0 27.0 28.0 5.1 8.7 21.7 42.0 72.3 116 174 246 318 5.1 7.59 12.7 25.3 36.2 21.7 72.3 109 137 195 203 0.16 0.20 0.24 0.31 0.39 0.47 0.55 0.55 0.67 0.16 0.20 0.24 0.31 0.39 0.24 0.39 0.55 0.67 0.67 0.67 4 5 6 8 10 12 14 14 17 4 5 6 8 10 6 10 14 17 17 17

Bolt size Torque Wrench size

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DISASSEMBLY

Select place suitable to disassembling. Select clean place.

Spread rubber sheet, cloth or so on on overhaul workbench top to prevent parts from being damaged.

Remove dust, rust, etc, from pump surfaces with cleaning oil or so on.

Remove drain port plug(468) and let oil out of pump casing(Front and rear pump). 3)

Place pump horizontally on workbench with its regulator-fitting surface down and separate pump casing(271) from valve block(312).

Before bringing this surface down, spread rubber sheet on workbench without fail to prevent this surface from being damaged. (1) ※ ※ (2) (3) (6) ※

Loosen hexagon socket head bolts(401) which tighten swash plate support(251), pump casing(271) and valve block(312). If gear pump and so on are fitted to rear face of pump, remove them before starting this work.

(5)

Remove hexagon socket head bolts(412, 413) and remove regulator.

(4)

(210-7) MP01

(24)

Pull cylinder block(141) out of pump casing(271) straightly over drive shaft(111). Pull out also pistons(151), set plate(153), spherical bush(156) and cylinder springs(157) simultaneously. Take care not to damage sliding surfaces of cylinder, spherical bushing, shoes, swash plate, etc.

(7)

Remove hexagon socket head bolts(406) and then seal cover(F, 261).

Fit bolt into pulling out tapped hole of seal cover(F), and cover can be removed easily.

Since oil seal is fitted on seal cover(F), take care not to damage it in removing cover.

Remove hexagon socket head bolts(408) and then seal cover(R, 262).

In case fitting a gear pump, first, remove gear pump.

Tapping lightly fitting flange section of swash plate support(251) on its pump casing side, separate swash plate support from pump casing.

(8) ※

(9)

Remove shoe plate(211)and swash plate(212) from pump casing(271). (11) (10) (210-7) MP03 (210-7) MP04 (210-7) MP05 (210-7) MP06

(25)

If necessary, remove stopper(L, 534), stopper(S, 535), servo piston(532) and tilting pin(531) from pump casing(271), and needle bearing(124) and splined coupling(114) from valve block(312). In removing tilting pin, use a protector to prevent pin head from being damaged. Since loctite is applied to fitting areas of tilting pin and servo piston, take care not to damage servo piston.

Do not remove needle bearing as far as possible, except when it is considered to be out of its life span.

Do not loosen hexagon nuts of valve block and swash plate support.

If loosened, flow setting will be changed. (14)

※ ※

Remove valve plates(313, 314) from valve block(312).

These may be removed in work(6). (13)

Tapping lightly shaft ends of drive shafts (111, 113) with plastic hammer, take out drive shafts from swash plate supports. (12)

(210-7) MP07

(26)

ASSEMBLY

For reassembling reverse the disassembling procedures, paying attention to the following items.

Do not fail to repair the parts damaged during disassembling, and prepare replacement parts in advance.

Clean each part fully with cleaning oil and dry it with compressed air.

Do not fail to apply clean working oil to sliding sections, bearings, etc. before assembling them.

In principle, replace seal parts, such as O-rings, oil seals, etc.

For fitting bolts, plug, etc., prepare a torque wrench or so on, and tighten them with torques shown in page 8-11, 12. For the double-pump, take care not to mix up parts of the front pump with those of the rear pump.

(1) 4) ① ② ③ ④ ⑤ ⑥

Fit swash plate support(251) to pump casing(271), tapping the former lightly with a hammer.

After servo piston, tilting pin, stopper(L) and stopper(S) are removed, fit them soon to pump casing in advance for reassembling.

In tightening servo piston and tilting pin, use a protector to prevent tilting pin head and feedback pin from being damaged. In addition, apply loctite(Medium strength) to their threaded sections.

(2)

(27)

Place pump casing with its regulator fitting surface down, fit tilting bush of swash plate to tilting pin(531) and fit swash plate (212) to swash plate support(251) correctly.

Confirm with fingers of both hands that swash plate can be removed smoothly. Apply grease to sliding sections of swash plate and swash plate support, and drive shaft can be fitted easily.

(3)

※ ※

Assemble piston cylinder subassembly 〔cylinder block(141), piston subassembly (151, 152), set plate(153), spherical bush (156), spacer(158) and cylinder spring (157)〕.

Fit spline phases of retainer and cylinder. Then, insert piston cylinder subassembly into pump casing.

(6)

Assemble seal cover(F, 261) to pump casing(271) and fix it with hexagon socket head bolts(406).

Apply grease lightly to oil seal in seal cover(F).

Assemble oil seal, taking full care not to damage it.

For tandem type pump, fit rear cover(263) and seal cover(262) similarly.

(5)

※ ※ ※

To swash plate support(251), fit drive shaft(111) set with bearing(123), bearing spacer(127) and snap ring(824).

Do not tap drive shaft with hammer or so on.

Assemble them into support, tapping outer race of bearing lightly with plastic hammer.

Fit them fully, using steel bar or so on. (4) ※ ※ (210-7) MP10 (210-7) MP11 (210-7) MP12 (210-7) MP13

(28)

Fit valve plate(313) to valve block(312), entering pin into pin hole.

Take care not to mistake suction / delivery directions of valve plate.

(7) ※

Putting feedback pin of tilting pin into feedback lever of regulator, fit regulator and tighten hexagon socket head bolts (412, 413).

Take care not to mistake regulator of front pump for that of rear pump.

(9)

Fit valve block(312) to pump casing(271) and tighten hexagon socket head bolts (401).

At first assemble this at rear pump side, and this work will be easy.

Take care not to mistake direction of valve block.

Clockwise rotation(Viewed from input shaft side) - Fit block with regulator up and with delivery flange left, viewed from front side.

Counter clockwise rotation(Viewed from input shaft side) - Fit block with delivery flange right, viewed from front side. (8)

※ ※ ※

Fit drain port plug(468).

This is the end of reassembling procedures. (10)

(210-7) MP14

(210-7) MP16

(29)

3. REGULATOR

STRUCTURE(1/2) 1) A A A B B B SECTION B-B P2 Pf Pm Pi KR3G-9C32 755 858 614 615 613 611 438 801 924 647 648 723 642 801 656 438 735 722 897 612 875 874 412 641 730 643 708 644 645 646 728 413 438 496 724 725 436 (210-7) 8-19

(30)

412 Hexagon socket screw 413 Hexagon socket screw 436 Hexagon socket screw 438 Hexagon socket screw 496 Plug

601 Casing

611 Feed back lever 612 Lever(1) 613 Lever(2) 614 Fulcrum plug 615 Adjust plug 621 Compensator rod 622 Piston case 623 Compensator rod 624 Spring seat(C) 625 Outer spring 626 Inner spring 627 Adjust stem(C) 628 Adjust screw(C) 629 Cover(C) 630 Nut 631 Sleeve 641 Pilot cover 642 Pilot cover(QMC) 643 Pilot piston 644 Spring seat(Q) 645 Adjust stem(Q) 646 Pilot spring 647 Stopper 648 Piston(QMC) 651 Sleeve 652 Spool 653 Spring seat 654 Return spring 655 Set spring 656 Block cover 708 O-ring 722 O-ring 724 O-ring 725 O-ring 728 O-ring 730 O-ring 732 O-ring 733 O-ring 734 O-ring 735 O-ring 755 O-ring 756 O-ring 763 O-ring 801 Nut 814 Snap ring 836 Snap ring 858 Snap ring 874 Pin 875 Pin 887 Pin 897 Pin 898 Pin 924 Set screw 925 Adjust screw(Q) REGULATOR(2/2) 734 653 654 836 651 652 601 624 629 630 628 655 641 814 898 631 732 733 622 C 801 925 627 732 621 623 625 626 887 763 756 SECTION A-A (210-7) 8-20

(31)

TOOLS AND TIGHTENING TORQUE Tools

The tools necessary to disassemble/reassemble the pump are shown in the follow list. 2)

(1)

Name

Adjustable angle wrench Screw driver Hammer Pliers Steel bar Torque wrench Pincers Bolt

Small size, Max 36mm

Minus type screw driver, Medium size, 2 sets Plastic hammer, 1 set

For snap ring, TSR-160 4×100mm

Capable of tightening with the specified torques

-M4, Length : 50mm

Tool name & size Part name

Hexagon socket head bolt PT plug (PT thread) PO plug (PF thread) Hexagon socket head setscrew M 5 M 6 M 8 Hexagon head bolt M 8 Hexagon nut M 8 VP plug (PF thread) -BP-1/16 BP-1/8 BP-1/4 -PO-1/4 M 8 M10 M12, M14 B B B 4 5 6 - 6 Allen wrench

Double ring spanner, socket wrench, double(Single)

(32)

Tightening torque (2)

Part name

Hexagon socket head bolt Material : SCM435)

PT Plut(Materal : S45C) ※Wind a seal tape 1 1/2 to 2

turns round the plug

PF Plut(Materal : S35C) M 5 M 6 M 8 M10 M12 M14 M16 M18 M20 PT1/16 PT 1/8 PT 1/4 PT 3/8 PT 1/2 PF 1/4 PF 1/2 PF 3/4 PF 1 PF 1 1/4 PF 1 1/2 0.7 1.2 3.0 5.8 10.0 16.0 24.0 34.0 44.0 0.7 1.05 1.75 3.5 5.0 3.0 10.0 15.0 19.0 27.0 28.0 5.1 8.7 21.7 42.0 72.3 116 174 246 318 5.1 7.59 12.7 25.3 36.2 21.7 72.3 109 137 195 203 0.16 0.20 0.24 0.31 0.39 0.47 0.55 0.55 0.67 0.16 0.20 0.24 0.31 0.39 0.24 0.39 0.55 0.67 0.67 0.67 4 5 6 8 10 12 14 14 17 4 5 6 8 10 6 10 14 17 17 17

Bolt size Torque Wrench size

(33)

DISASSEMBLY

Since the regulator consists of small precision finished parts, disassembly and assembly are rather complicated.

For this reason, replacement of a regulator assembly is recommended, unless there is a special reason, but in case disassembly is necessary for an unavoidable reason, read through this manual to the end before starting disassembly.

Choose a place for disassembly. Choose a clean place.

Spread rubber sheet, cloth, or so on on top of work-bench to prevent parts from being damaged.

Remove dust, rust, etc. from surfaces of regulator with clean oil.

(1) ※ ※

(2) 3)

Remove hexagon socket head screw (438) and remove cover(C,629)

Cover(C) is fitted with adjusting screw (C,QI) (628, 925), adjusting ring(C, 627), lock nut(630), hexagon nut(801) and adjusting screw(924).

Do not loosen these screws and nuts. If they are loosened, adjusted pressure-flow setting will vary.

(4) ※

Remove hexagon socket head screw (412, 413) and remove regulator main body from pump main body.

Take care not to lose O-ring. (3)

(210-7) REG01

(34)

Remove locking ring(858) and take out fulcrum plug(614) and adjusting plug (615).

Fulcrum plug(614) and adjusting plug (615) can easily be taken out with M6 bolt. (8)

Remove snap ring(814) and take out spring seat(653), return spring(654) and sleeve(651).

Sleeve(651) is fitted with snap ring(836). When removing snap ring(814), return spring(654) may pop out.

Take care not to lose it. (7)

※ ※

Remove hexagon socket head screws (436, 438) and remove pilot cover(641). After removing pilot cover, take out set spring(655) from pilot section.

(6)

After removing cover(C, 629) subassembly, take out outer spring(625), inner spring (626) and spring seat(C, 624) from compensating section.

Then draw out adjusting ring(Q, 645), pilot spring(646) and spring seat(644) from pilot section.

Adjusting ring(Q,645) can easily be drawn out with M4 bolt.

(5) ※ (210-7) REG03 (210-7) REG04 (210-7) REG05 (210-7) REG06

(35)

Draw out pin(874) and remove feedback lever(611).

Push out pin(874, 4mm in dia.) from above with slender steel bar so that it may not interfere with lever(1, 612).

(10)

Remove lever(2, 613). Do not draw out pin(875).

Work will be promoted by using pincers or so on. (9) ※ (210-7) REG07 (210-7) REG08 (210-7) REG09 (210-7) REG10

(36)

Remove lever(1, 612). Do not draw out pin(875).

Draw out pilot piston(643) and spool(652). Draw out piston case(622), compensating piston(621) and compensating rod(623). Piston case(622) can be taken out by pushing compensating rod(623) at opposite side of piston case.

This completes disassembly. (11)

(12) (13) ※

(37)

ASSEMBLY

For assembly, reverse disassembly procedures, but pay attention to the following items.

Always repair parts that were scored at disassembly.

Get replacement parts ready beforehand. Mixing of foreign matter will cause malfunction.

Therefore, wash parts well with cleaning oil, let them dry with jet air and handle them in clean place.

Always tighten bolts, plugs, etc. to their specified torques.

Do not fail to coat sliding surfaces with clean hydraulic oil before assembly. Replace seals such as O-ring with new ones as a rule. (1) ① ② ③ ④ ⑤ 4) Spool Feedback lever

Put compensating rod(623) into compensating hole of casing(601). Put pin force-fitted in lever(1, 612) into groove of compensating rod and fit lever (1) to pin force-fitted in casing.

(2)

(3)

Fit spool(652) and sleeve(651) into hole in spool of casing.

Confirm that spool and sleeve slide smoothly in casing without binding. Pay attention to orientation of spool. (4)

※ ※

(38)

Lever (1) side Lever (2) side (Fulcrum plug of adjusting plug side)

Fit return spring(654) and spring seat (653) into spool hole and attach snap ring (814).

(10)

Fit fulcrum plug(614) so that pin force-fitted in fulcrum plug(614) can be put into pin hole of lever(2).

Then fix locking ring(858).

Insert adjusting plug(615) and fit locking ring.

Take care not to mistake inserting holes for fulcrum plug and adjusting plug. At this point in time move feedback lever to confirm that it has no large play and is free from binding.

(8)

(9) ※

Put pilot piston(643) into pilot hole of casing.

Confirm that pilot piston slides smoothly without binding.

Put pin force-fitted in lever(2, 613) into groove of pilot piston.

Then fix lever(2). (6)

※ (7)

Fit feedback lever(611), matching its pin hole with pin hole in spool.

Then insert pin(874).

Insert pin in feedback lever a little to ease operation.

Take care not to mistake direction of feedback lever. (5) ※ ※ (210-7) 8-28 (210-7) REG11 (210-7) REG12 (210-7) REG13

(39)

Install cover(C, 629) fitted with adjusting screws(628, 925), adjusting ring(C, 627), lock nut(630), hexagon nut(801) and adjusting screw(924).

Then tighten them with hexagonal socket head screws(438).

This completes assembly. (13)

Put spring seat(644), pilot spring(646) and adjusting ring(Q, 645) into pilot hole. Then fix spring seat(624), inner spring (626) and outer spring(625) into compensating hole.

When fitting spring seat, take care not to mistake direction of spring seat.

(12)

Fit set spring(655) to spool hole and put compensating piston(621) and piston case(622) into compensating hole. Fit pilot cover(641) and tighten it with hexagonal socket head screws(436, 438). (11)

(210-7) REG14

(210-7) REG15

Figure

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References

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